Roofing membranes having multiple adhesive regions and method therefor

ABSTRACT

A roofing membrane may include a main body, a first material, and a second material. The first material may be bonded to the main body and positioned toward a first edge thereof. The second material may be bonded to the main body and positioned toward a second edge thereof. The second edge may be positioned opposite the first edge such that the first and second materials are positioned toward opposite edges of the main body. At least one of the first material or the second material may include a first reactive material of a chemically reactive two-part cure system that is configured to chemically react upon contact of the first reactive material with a second reactive material of the chemically reactive two-part cure system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/831,637 filed Aug. 20, 2015, which is a continuation-in-part of U.S.patent application Ser. No. 14/180,831 filed Feb. 14, 2014, now U.S.Pat. No. 9,234,352, issued Jan. 12, 2016, the entire disclosure of whichis hereby incorporated by reference, for all purposes, as if fully setforth herein.

BACKGROUND OF THE INVENTION

Roofing membranes are commonly used for roofing systems of building andstructures. Roofing membranes are often applied to the building orstructure's roof to prevent leaks and/or to provide aesthetic appeal.Roofing membranes are commonly made of various synthetic rubbermaterials, modified bitumen, or thermoplastic materials.

Two common types of roofing membrane include those made of thermoplasticpolyolefin (TPO) and those made of ethylene propylene diene monomerrubber (EPDM). TPO membranes are often white, but may be made in variousother colors or shades, such as grey, black, and the like. Similarly,EPDM membranes are often black, but in some embodiments may also bewhite. White roofing membranes are often used to provide a pleasingvisual appeal and/or to reflect radiation and thereby minimize heatisland effects. Individual sections of EPDM membranes are often bondedtogether by priming or preparing an edges of the EPDM membranes and thenapplying a tape to the primed or prepared edges. Individual sections ofTPO membranes are often coupled together by overlapping adjacent edgesand heat welding the edges together. TPO may also be bonded by primingadjacent edges and using a tape.

BRIEF SUMMARY OF THE INVENTION

The embodiments described herein provide roofing membranes that may beeasily installed atop a roof. Installation of the roofing membranes issimplified by the incorporation of materials on ends or edges of theroofing membrane. Each material is configured to aid in attaching theroofing membrane with a roof surface and/or an adjacent roofingmembrane. According to one aspect, a roofing membrane includes a mainbody having: a top surface, a bottom surface positioned opposite the topsurface, and four edges that define an outer periphery of the main bodysuch that the main body has a rectangular or square profile. The roofingmembrane also includes a first material bonded to the main body andpositioned toward a first edge thereof and a second material bonded tothe main body and positioned toward a second edge thereof. The firstmaterial extends along a majority of a length of the first edge and thesecond material extends along a majority of a length of the second edge.The second edge is positioned opposite the first edge such that thefirst and second materials are positioned toward opposite edges of themain body on optionally on opposite surfaces thereof. At least one ofthe first material or the second material comprises a first reactivematerial of a chemically reactive two-part cure system that isconfigured to chemically react upon contact of the first reactivematerial with a second reactive material of the chemically reactivetwo-part cure system.

In some embodiments, the first material may be positioned on one surfaceof the main body and the second material may be positioned on anopposite surface of the main body. The first material may be or includethe first reactive material and the second material may be or includethe second reactive material so that the roofing membrane includes bothmaterials of the chemically reactive two-part cure system positioned onopposite edges of the main body. The first reactive material may beapplied as a liquid directly to the roofing membrane surface, may beapplied as a tape to the roofing membrane surface, or may be saturatedin a carrier that is attached to the roofing membrane.

In some embodiments, the first material may be an adhesive tape and thesecond material may be or include the first reactive material. In suchembodiments, the first reactive material may be applied as a liquiddirectly to the roofing membrane surface. The first material (e.g.,adhesive tape) may be bonded to the main body such that an edge of thefirst material is laterally offset from an edge of the main body. Theroofing membrane may be folded in a z-configuration with the foldedsection of the roofing membrane being disposed between the firstmaterial and the second material.

According to another aspect, a roof membrane system may include a firstmembrane that is positioned atop the roof. The first membrane may have adistal edge that includes a first reactive material on a top surfacethereof. The first reactive material may extend along a majority of alength of the distal edge. The roof membrane system may also include asecond membrane that is positioned atop the roof and adjacent the firstmembrane so that a proximal edge of the second membrane overlaps withand is bonded to the distal edge of the first membrane. The proximaledge of the second membrane may include a second reactive material on abottom surface thereof. The second reactive material may extend along amajority of a length of the proximal edge. The first reactive materialand the second reactive material may be configured to chemically reactand cure upon contact with one another to bond the distal edge of thefirst membrane to the proximal edge of the second membrane. The firstand second reactive materials may be configured not to cure prior tocontact with the other reactive material.

In some embodiments, the roof membrane system may include a firstmembrane material that is releasably coupled with a top surface of thefirst reactive material and a second membrane material that isreleasably coupled with a top surface of the second reactive material.In some embodiments, the first reactive material and/or the secondreactive material may be resins. The first reactive material and/or thesecond reactive material may be applied as a liquid directly to therespective membrane. In other instances, the first reactive materialand/or the second reactive material may be applied as a tape to therespective membrane, or may be saturated in a carrier that is attachedto the respective membrane. The first reactive material may be appliedas a liquid directly to the first membrane and the second reactivematerial may be applied as a tape to the second membrane or may besaturated in a carrier that is attached to the second membrane.

According to another aspect, a roofing membrane includes a main bodyhaving: a top surface, a bottom surface positioned opposite the topsurface, and four edges that define an outer periphery of the main bodysuch that the main body has a rectangular or square profile. The roofingmembrane may include a first material that is bonded to the main bodyand positioned toward a first edge thereof and a second material that isbonded to the main body and positioned toward a second edge thereof. Thefirst material may extend along a majority of a length of the first edgeand the second material may extend along a majority of a length of thesecond edge. The second edge may be positioned opposite the first edgesuch that the first and second materials are positioned toward oppositeedges of the main body.

In some embodiments, the first material may be an adhesive tape that isbonded with the roofing membrane. In such embodiments, the roofingmembrane may further include a mechanical fastening member that isadhesively bonded with a top surface of the adhesive tape. Themechanical fastening member may be configured to receive a mechanicalfastener to secure the roofing membrane to a roof surface. In otherembodiments, the first material may be a mechanical fastening memberthat is configured to receive a mechanical fastener to secure theroofing membrane to a roof surface. The mechanical fastening member maybe coupled with the roofing member prior to transport of the roofingmember to an installation site. In yet other embodiments, the firstmaterial may include a pair of adhesive tapes that are bonded to themain body and that are positioned toward the first edge with a gapexisting between the inner sides or edges of the pair of adhesive tapes.The gap may be sized so that a mechanical fastening member may bepositioned therein. The mechanical fastening member may be configured toreceive a mechanical fastener to secure the roofing membrane to a roofsurface.

The roofing membrane may additionally include a releasable liner that ispositioned and removably secured atop the first material. The releasableliner may include at least one scored or perforated region that isindependently removable from a main body of the releasable liner. Insuch embodiments, the scored or perforated region of the releasableliner is positioned with respect to the main body of the releasableliner so as to aid in alignment of a mechanical fastening member withthe first material. The mechanical fastening member may be configured toreceive a mechanical fastener to secure the roofing membrane to a roofsurface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in conjunction with the appendedfigures:

FIG. 1 illustrates a perspective view of an embodiment of a roofingmembrane having multiple adhesive regions.

FIG. 2 illustrates a side view of an embodiment of a roofing membranehaving multiple adhesive regions.

FIG. 3 illustrates a side view of another embodiment of a roofingmembrane having multiple adhesive regions.

FIG. 4 illustrates a side view of an embodiment of a first roofingmembrane and a second roofing membrane coupled together as part of aroofing system.

FIG. 5 illustrates a side view of another embodiment of a first roofingmembrane and a second roofing membrane coupled together as part of aroofing system.

FIG. 6 illustrates a method of coupling roofing membranes atop a roof aspart of a roofing system.

FIGS. 7A-C illustrate a roofing membrane having a pre-applied adhesivetape that facilitates in application of a mechanical fastening componentto the roofing membrane.

FIGS. 8A-C illustrate another roofing membrane having a pre-appliedadhesive tape that facilitates in application of a mechanical fasteningcomponent to the roofing membrane.

FIGS. 9A and 9B illustrate releasable liners that may be used to coverand protect adhesive tapes of roofing membranes.

FIGS. 10A-C illustrate a roofing membrane having a reactive materialapplied to opposite surfaces and opposite faces of the roofing membrane.

FIGS. 11A and 11C illustrate folding orientations that may be employedto alleviate issues associated with rolling a roofing membrane.

FIG. 11B illustrates a roofing membrane having a filler strip that isplaced on an opposite side of the roofing membrane from a pre-appliedtape.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides exemplary embodiments only, and is notintended to limit the scope, applicability or configuration of thedisclosure. Rather, the ensuing description of the exemplary embodimentswill provide those skilled in the art with an enabling description forimplementing one or more exemplary embodiments. It being understood thatvarious changes may be made in the function and arrangement of elementswithout departing from the spirit and scope of the invention as setforth in the appended claims.

The embodiments described herein provide roofing membranes that may beeasily installed atop a roof. Installation of the roofing membranes issimplified by the incorporation of adhesive material and/or tape layerson opposing ends or edges of the roofing membrane. Each adhesivematerial and/or tape layer is positioned on an opposing surface of theroofing membrane in order to allow the edges of adjacent membranes to beoverlapped and coupled or bonded together. For convenience in describingthe embodiments herein, the adhesive material and/or tape will begenerally described as an adhesive material or adhesive layer. It shouldbe realized, however, that the description of the adhesive material orlayer may encompass a variety of adhesives and/or tape layers. In someembodiments, the tapes and/or adhesive materials may be of the samematerial composition or could formed of various compositions includingbut not limited to reactive chemistries, pressure sensitive systems, andthe like.

A releasable tape or liner may be releasably coupled to each of theadhesive materials to limit environmental exposure of the adhesivematerial and thereby maintain the adhesive properties of the material.The releasable liner of adjacent membranes may be easily removed at thejob site prior to coupling of the membranes. The use of the releasableliner eliminates, or greatly reduces, the need for priming orpreparation of the roofing membranes prior to coupling of the membranes.For example, an installer does not need to apply a solvent or solutionto the roofing membrane in order to remove debris, oils, or othercontamination that may impede or alter the coupling or bonding ofadjacent roofing membranes. The elimination or reduction of thisinstallation step greatly decrcases the time in which a roof membranesystem may be installed.

As used herein, the term roofing membrane means essentially any materialthat is installed atop a roof, typically as an outer surface or layer.Such roofing membranes are commonly installed for various functionaland/or aesthetic purposes. For example, roofing membranes may beinstalled to provide weather proofing, reduce urban heat island effectsvia heat reflection, reduce UV damage, reduce roof maintenance and/ordegradation, improving weathering characteristics, and the like. Roofingmembranes may also provide a sleek and/or desired roof appearance, suchas a uniform roof color and/or style.

Common roofing membranes include various thermoset materials, such asethylene propylene diene monomer rubber (EPDM), modified bitumen, andvarious thermoplastic materials, such as Thermoplastic PolyOlefin (TPO).The embodiments described herein may find particular usefulness forroofing membranes constructed or EPDM, modified bitumen, and/or TPOmaterials, although the embodiments may be used for other thermosetand/or thermoplastic roofing membranes as desired.

Roofing systems often include various materials and/or layers inaddition to the roofing membranes. These layers/materials are typicallypositioned under the roofing membrane and may include support members(e.g., wood and/or metal beams), insulation layers (e.g., form and/orother insulating boards), and/or other boards or members. The roofingmembrane may be coupled with one or more of these materials viaballasting, mechanically fastening, adhesive bonding, heat welding, andthe like.

Conventional roofing membranes are typically coupled together byoverlapping adjacent edges, preparing or priming one or more edges, andthen using an adhesive material to bond the adjacent edges or heatwelding the adjacent edges together. In priming or preparing the edges,the installer must wait for the primer material to flash before applyingthe adhesive. Improper application of the primer and/or adhesive mayresult in an improper bond, which may create immediate and/or long termroofing problems, such as leakage. Human error, such as non-uniformapplication of the primer and/or adhesive material, may also result ininadequate or insufficient membrane adhesion, which may create shortterm and/or long term problems. These and other issues are reduced oreliminated via the roofing membrane embodiments described herein.

Referring now to FIG. 1, illustrated is an embodiment of a roofingmembrane 100 that may be constructed of a thermoset material (e.g.,EPDM), modified bitumen, or a thermoplastic material (e.g., TPO).Roofing membrane 100 includes a main body 102 having a top surface and abottom surface positioned opposite the top surface. Main body 102 alsoincludes for edges that defining an outer periphery of main body 102.Main body 102 typically has a square or rectangular profile. In manyinstances, main body 102 may have a lateral width of between about 10and 40 feet, a longitudinal length of between about 50 and 100 feet, anda thickness of between about 0.045 and 0.090 inches, although it shouldbe realized that these dimensions may vary depending on the applicationand/or need.

A first adhesive material or tape is bonded to, coupled to, or otherwisepositioned atop the top surface of the main body 102. The first adhesivematerial or tape is positioned toward a first edge of the main body 102and forms and adhesive material strip 104 or layer (hereinafter adhesivestrip 104) atop the top surface of main body 102. The adhesive strip 104extends along a majority of the first edge's length, and commonly alongthe entire length between opposing ends. The description of the adhesivestrip 104 extending along the entire length of the first edge betweenopposing ends includes situations where the strip 104 is slightlyshorter than the length of the first edge. For example, in someembodiments, the strip 104 may be coupled or bonded to the main body 102between 3 and 6 inches short of an edge of the main body. In suchembodiments, the last 3 to 6 inches on the end laps may be taped oradhered by a contractor or installer. The adhesive strip 104 is commonlybetween about 3 and 6 inches wide, although in some embodiments thestrip 104 may be between ½ and 8 inches wide. The adhesive strip 104 mayalso be between 0.005 and 0.030 inches, and may be positioned withrespect to main body 102 so that an edge of the adhesive strip 104 isaligned with, or offset from, the first edge as described in greaterdetail herein below. In other embodiments, the adhesive strip 104 may beinset from the first edge so that the first edge protrudes or extendslaterally beyond the adhesive strip 104. In other embodiments, adhesivestrip 104 may have a width greater than 6 inches or less than 3 inchesas desired.

A second adhesive material or tape is bonded to, coupled to, orotherwise positioned atop the bottom surface of main body 102. Thesecond adhesive material or tape is positioned toward a second edge ofthe main body 102 and forms an adhesive material strip 106 or layer(hereinafter adhesive strip 106) atop the bottom surface of main body102. Like adhesive strip 104, adhesive strip 106 extends along amajority of the second edge's length, and commonly along the entirelength between opposing ends. Adhesive strip 106 commonly has a width ofbetween 3 and 6 inches, although other widths may be employed. Adhesivestrip 106 may also be aligned with or offset from the second edge ofmain body 102 as desired. Alternatively, adhesive strip 106 may be insetfrom the second edge of main body 102 as described herein.

The second edge is positioned on an opposite side of main body 102 fromthe first edge so that opposing edges or ends of the main body 102include the adhesive strips, 104 and 106. Further, the adhesive strips,104 and 106, are positioned on opposing surfaces of the main body 102 toaid in coupling of adjacent roofing membranes 100 as described hereinbelow. A releasable liner or tape is normally coupled with a top surfaceof the adhesive strips to prevent or limit environmental exposure of theadhesive material, which may degrade the adhesive material or otherwisecompromise or interfere with bonding of the adhesive material. Thereleasable liner may also prevent premature drying or hardening of theadhesive material. The releasable liner may be constructed of a polymeror other material membrane, such as coated paper, metalized film, coatedfabric, and the like, that releasably adheres to the adhesive material.

As shown in FIG. 1, a first liner or membrane 108 may be releasablycoupled with adhesive strip 104 and a second liner or membrane 110 maybe releasably coupled with adhesive strip 106. The liners, 108 and 110,may be sized slightly larger than the respective adhesive strips, 104and 106, to allow the liners to fully cover and conceal the adhesivematerial. The slightly larger liners, 108 and 110, also make it easierfor an installer to grasp an edge of the liner and remove the liner fromthe respective adhesive strips, 104 and 106, prior to or duringinstallation of the roofing membrane 100.

The use of the adhesive strips, 104 and 106, on roofing membrane 100decrcases the amount of time required to install the membrane 100onsite. For example, the adhesive strips, 104 and 106, eliminates theneed for a contractor or installer to prime or prepare edges of theroofing membrane 100 in order to bond the roofing membrane 100 with anadjacent membrane. As such, an installer does not need to wait for theprimer to flash, thereby decreasing the installer's wait time andallowing the installer to move on to the next stage of installation.Further, the adhesive strips, 104 and 106, may be bonded to therespective surfaces of main body 102 as part of the manufacturingprocess of the roofing membrane 100. Accordingly, the manufacturer hasincrcased control over the bonding element or layer that is ultimatelyused in forming the roofing system, thereby eliminating or reducinghuman error and/or increasing the likelihood that the bonding element orlayer is properly prepared. This may result in improved bonding betweenadjacent roofing membranes thereby minimizing or eliminating some or allof the short-term and long-term issues described above.

Referring now to FIG. 2, illustrated is another embodiment of a roofingmembrane 200. Roofing membrane 200 is similar to membrane 100 in thatmembrane 200 has a main body 202 that includes a first adhesive strip204 positioned on one side of the main body 202 and a second adhesivestrip 208 positioned on an opposite side of the main body 202. Asdescribed above, the adhesive strips, 204 and 208, are positioned onopposing surfaces of main body 202. A releasable tape or liner 206 isreleasably coupled atop the first adhesive strip 204 while a releasabletape or liner 210 is releasably coupled atop the second adhesive strip208. FIG. 2 illustrates that the adhesive strips, 204 and 208, may beapplied so as to have a relatively equal thickness and width on theopposing sides and surfaces of main body 202.

Employing relatively equal thickness and width adhesive strips, 204 and208, may eliminate or reduce common problems associated with rolling upthe membrane 200 for transportation and/or storage. For example, ifmembrane 200 includes only one adhesive strip material (i.e., 204 or210), as the membrane 200 is rolled about a core, the single adhesivestrip may cause the thickness of the roll to incrcase disproportionatelyon one side of the core, thereby varying the thickness of the rollproduct across the web of the roll. A varying thickness of the rollproduct may cause the roll product to telescope about the core duringwind up and/or cause the membrane 200 to curve or bend as it is beingunrolled atop a roof. In contrast, by applying the adhesive strips, 204and 208, to opposing ends and/or surfaces of main body 202, theresulting roll product has a relatively equal thickness about the core,which aids in preventing telescoping during wind up and/or aids inkeeping the membrane 200 straight as it is rolled out atop a roof.

Referring now to FIG. 3, illustrated is another embodiment of a roofingmembrane 300 having a main body 302 with an adhesive strip 304positioned on one side of the main body 302 and another adhesive strip308 positioned on an opposite side and opposite surface of the main body302 as described above. Releasable liners, 306 and 310, are releasablycoupled with a top surface of the respective adhesive strips, 304 and308. The adhesive strips, 304 and 308, are different from thosepreviously described in that the strips having varying widths and/orthicknesses. For example, adhesive strips 304 has a width of Y and athickness of B while adhesive strip 308 has a width of X and a thicknessof A. The widths and/or thicknesses of the respective adhesive strips,304 and 308, may be within the ranges previously described. In someembodiments, the widths, Y and X, of the adhesive strips, 304 and 308respectively, may vary, while in other embodiments the thicknesses, Band A, of the adhesive strips, 304 and 308 respectively, may vary. Insome embodiments, both the widths and the thicknesses of the adhesivestrips, 304 and 308, may vary.

Varying the widths and/or thicknesses of the adhesive strips, 304 and308, may aid in coupling of adjacent roofing membranes and/or forming aroofing membrane system about a uniquely shaped roof. For example, widerand/or thinner adhesive strips (e.g., adhesive strip 304) may be usedwhen a greater bonding surface area is desired while narrower and/orthicker adhesive strips (e.g., adhesive strips 308) may be used when anedge of the roofing membrane 300 is butted up against a corner of theroof. In some embodiments, the roofing system formed atop a roof mayinclude a combination of roofing membranes having relatively equal sizedadhesive strips and roofing membranes having relatively unequal sizedadhesive strips as needed.

Referring now to FIGS. 4-5, illustrated are embodiments in whichadjacent roofing membranes are coupled or bonded together to form aroofing system. For example, FIG. 4 illustrates a roofing system 400formed of a bonded or coupled first roofing membrane 402 and secondroofing membrane 404. The first and second roofing membranes, 402 and404, may be constructed similarly to those described herein above havinga main body with opposing ends and surfaces having an adhesive strip. Incoupling or bonding the adjacent membranes, 402 and 404, a distal edgeof membrane 402 is overlapped with a proximal edge of membrane 404 sothat the adhesive materials, 406 and 408, of the respective membranesare vertically aligned. The releasable liners (not shown) of theadhesive materials, 406 and 408, may then be removed and the adhesivematerials pressed together to couple or bond the membranes, 402 and 404,together. The adhesive strips, 406 and 408, bond well togethereliminating the need to prime any membrane surface for bonding strength.

As shown in FIG. 4, the adhesive strips, 406 and 408, may be alignedrelative to one another so that a proximal edge 410 and/or a distal edge412 of each adhesive strip, 406 and 408, is aligned. Stated differently,the proximal edge 410 and/or distal edge 412 of the coupled strips, 406and 408, may be relatively flush after the membranes, 402 and 404, arecoupled together. Similarly, adhesive strip 406 and/or adhesive strip408 may be offset 414 from the edge of the respective membrane, 402 and404. In some embodiments, the adhesive strip or strips may be offset 414from the respective membrane by between about 1/16 and ¼ of an inch, andmore commonly by about ⅛ of an inch. Alternatively, the adhesive stripor strips may be inset from the respective membrane by between about1/16 and ¼ of an inch, and more commonly by about ⅛ of an inch.

Offsetting the adhesive strips from the respective membranes in thismanner may allow a contractor or installer to quickly and easilyvisually inspect the adhesive bond between the membranes, 402 and 404,and/or to determine that the coupled membranes provide a sufficientwaterproofing layer. For example, after installation of the roofingsystem, a contractor or installer may quickly and easily traverse theroofing membranes' seams and inspect the bond between the coupledmembranes by inspecting the portion of the adhesive strips that protrudefrom the seams. The contractor or installer may determine if any gaps orother irregularities exist in the coupled adhesive layers and/or betweenthe adhesive layer and the respective membrane. The contractor orinstaller may also visually determine whether the coupled membranes aresufficiently waterproof by inspecting the protruding adhesive strips forgaps, cracks, separations, or any other defects that may signal anincomplete or otherwise improper bond between the adjacent membranesand/or adhesive layers that may result in water leakage or otherpotential problems.

The protrusion of the adhesive strips, 406 and 408, from the seam of thecoupled membranes, 402 and 404, may also improve the waterproofingcharacteristics of the membrane system. For example, the protrudingadhesive strip material may minimize or eliminate gaps that mayotherwise be formed under the coupled membranes' seam within which waterand/or ice may penetrate and cause leakage or other problems. In thismanner, the protruding adhesive strip material may function similar tocaulking to effectively seal the seams and may eliminate the need for aseparate caulking step to be performed.

FIG. 5 illustrates another embodiment of a roofing system 500 having afirst roofing membrane 502 bonded or coupled with a second roofingmembrane 504. Similar to roofing system 400, the membranes, 502 and 504,of system 500 are bonded by aligning and pressing together respectiveadhesive strips, 506 and 508. Unlike system 400, however, the adhesivestrip 506 of membrane 502 is aligned with membrane 502's distal edge 514while the adhesive strip 508 of membrane 504 is offset from membrane504's proximal edge 516. The difference in alignment of the adhesivestrips, 506 and 508, results in an offset or staggered alignment of thecoupled adhesive strips proximal edge 510 and/or distal edge 512. Thisstaggered relationship of the adhesive strips may aid in the visualinspection of the coupled membranes by visually delineating the bondinginterface between the adhesive strips, 502 and 504. The staggeredrelationship of the adhesive strips may also minimize or eliminateformation of folds or defects during installation, which may improve thewaterproofing ability of the system 500. For example, the tape (e.g.,butyl tape) is typically soft and easily deforms. In contrast, curedEPDM membranes typically have some stiffness and body so that they willnot fold or crcase as easily as the tape. As such, the cured EPDMmembrane holds the tape in place, thus decreasing the chance for defectsto form in the tape.

In any event, one of the adhesive strips should protrude from the seamof coupled membranes, 502 and 504, by between about 1/16 and ¼ inch, andmore commonly by about ⅛ inch to provide the visual inspection and/orwaterproofing benefits previously described. Preferably the bottom orlower adhesive strip (i.e., adhesive strip 508 in FIG. 5) protrudes fromthe seam to prevent formation of gaps within which water or ice maypenetrate.

Referring now to FIG. 6, illustrated is a method 600 of coupling roofingmembranes atop a roof. The roofing membranes may be similar to any ofthose described herein. At step 610, a first membrane is positioned atopthe roof and at step 620, a second membrane is positioned atop the roof.At step 630, a proximal edge of the second membrane is overlapped with adistal edge of the first membrane. As described herein, the distal edgeof the first membrane includes a first adhesive material on a topsurface thereof that extends along a majority of a length of the distaledge and the proximal edge of the second membrane includes a secondadhesive material on a bottom surface thereof that extends along amajority of a length of the proximal edge. At step 640, the firstadhesive material is bonded with the second adhesive material to couplethe first and second membranes together atop the roof.

In some embodiments, the method further includes removing a membranematerial from either or both the first adhesive material or the secondadhesive material. As described herein, the membrane material limits theenvironmental exposure of the adhesive material. In some embodiments,the first adhesive material and the second adhesive material haveroughly the same width. In other embodiments, the width of the firstadhesive material may be smaller than the width of the second adhesivematerial or vice versa.

In some embodiments, the method may also include aligning the firstadhesive material with the second adhesive material so that an edge ofthe first adhesive materials aligns with an edge of the second adhesivematerial. In other embodiments, the method may include aligning thefirst adhesive material with the second adhesive material so that anedge of the first adhesive materials is offset from an edge of thesecond adhesive material. In any of the embodiments, the method mayadditionally include coupling either or both the first membrane or thesecond membrane with the roof via ballasting, mechanically fastening,heat welding, adhesive bonding, and the like.

In some embodiments, the roofing membrane (e.g., EPDM, TPO, modifiedbitumen, etc.) may be attached with a mechanical fastener or fasteningsystem. For example, a strip, plate, bar, or other component of materialmay be atop one or more edges of the roofing membrane and used tomechanically secure the roofing membrane to the roof surface. The strip,plate, bar, or other fastening component may include precut holesthrough which a mechanical fasteners, such as a bolt or screw, isinserted. In some embodiments, the adhesive tape may aid in securing thestrip, plate, bar, or other fastening component to the roofing membrane.In other embodiments, the strip, plate, bar, or other fasteningcomponent is pre-assembled with the roofing membrane. The strip, plate,bar, or other fastening component may be used to secure the roofingmembrane (often a single-ply membrane) to steel, wood, concrete, gypsum,and other cementitious decks. An example of the strip, plate, bar, orother fastening component that may be used to mechanically secure theroofing membrane is a batten bar (hereinafter batten bar). For case indescribing the embodiments herein, the strip, plate, bar, or otherfastening component will be referred to generally as a mechanicalfastening component or member.

The mechanical fastening component may be made of various types of metalmaterials, polymer materials, and the like. When metal materials areemployed, the edges, corners, and precut holes are typically roundedand/or deburred. The polymer mechanical fastening component may beparticularly useful in attached the roofing membrane to steel, wood, andstructural concrete roof decks. The pre-applied adhesive strips or tape(hereinafter adhesive tape) that is applied at the seams of the roofingmembrane as described herein, decrcases the amount of time required toinstall the roofing membrane on site when a mechanical fasteningcomponent is used. Specifically, the pre-applied adhesive tapeeliminates the time required to wait for the tape primer to flash, thusdecreasing a contractor's overall installation time by allowing the jobto progress quickly to the mechanical fastening stage or other stages.The pre-applied adhesive tape, which may be applied on a single side orboth sides of the roofing membrane, eliminates the need for thecontractor to prime the membrane prior to application of the mechanicalfastening component.

Referring now to FIGS. 7A-C, illustrated is an embodiment 700 of aroofing membrane 702 having a pre-applied adhesive strip or tape 704(hereinafter adhesive tape 704) that is configured to facilitate inapplication of a mechanical fastening component that is used to attachor secure the roofing membrane 702 to the roof surface. The adhesivetape 704 may be configured and/or arranged similar to any of theembodiments described herein. Specifically, the adhesive tape 704 ispre-applied to at least one side of the roofing membrane 702, and oftento both sides on opposite faces or surfaces and opposite sides of theroofing membrane 702 as illustrated. A releasable liner 706 is attachedto a top surface of the adhesive tape 704 to protect the tape 704 andprevent degradation or contamination of the adhesive material. Anexemplary releasable liner 902 that may be used with the roofingmembrane 702 is illustrated in FIG. 9A. The releasable liner 902 may aida contractor in applying a mechanical fastening component atop theadhesive tape 704.

FIG. 7B illustrates a mechanical fastening component 708 beingpositioned atop and adhesively bonded to the adhesive tape 704. Themechanical fastening component 708 includes at least one hole 710, andtypically includes a plurality of holes 710. The holes 710 are formedinto the mechanical fastening component 708 and serve as attachment orsecuring locations for mechanical fasteners, such as bolts, screws, andthe like. The mechanical fastening component 708 may be formed withvarious standard or custom hole spacing, including 3-inch on center,6-inch on center, 12-inch on center, and the like. In installing themechanical fastening component 708, an installer removes the releasableliner 706 from the adhesive tape 704 and then install the mechanicalfastening component 708 over and atop the adhesive tape 704. Asillustrated in FIG. 7B, the mechanical fastening component 708 istypically applied to one face or surface (i.e., the top face) and oneside of the roofing membrane 702. The opposite or other adhesive tape704 is typically free of a mechanical fastening component 708 and isable to attach and adhesively bond with an adhesive tape 704 and/ormechanical fastening component 708 of a separate and adjacent roofingmembrane.

In other embodiments, the roofing membrane 702 may include twomechanical fastening components 708. Specifically, separate mechanicalfastening components 708 may be attached to the opposite faces/surfacesand opposite sides of the roofing membrane 702 so that the roofingmembrane 702 includes two mechanical fastening component 708 on bothsurfaces and on opposite sides. Other arrangement or configurations arealso possible, such as two mechanical fastening components 708 on thesame surface and opposite sides, two mechanical fastening components 708on the same (or opposite) surfaces and on adjacent sides, and the like.The latter configuration may be particularly useful when the roofingmembrane 702 is being attached to a corner of the roof surface.

In some embodiments, the mechanical fastening component 708 ispre-applied to the roofing membrane 702, which eliminates the need forthe installer to apply the mechanical fastening component. In suchembodiments, the releasable membrane 706 may be positioned atop themechanical fastening component 708 so that the installer need onlyremove the releasable liner 706 and then mechanically fasten the roofingmembrane 702 to the roof surface. A second roofing membrane may then beattached to the roofing membrane 702 having the pre-applied mechanicalfastening component 708. The mechanical fastening component 708 may becoupled with the roofing membrane 702 using the adhesive tape 704 and/orusing any other fastening or adhesive technique known in the art.

FIG. 7C illustrates a first roofing membrane 702 a coupled with a secondroofing membrane 702 b atop a roof surface. A mechanical fasteningcomponent 708 is attached to the first roofing membrane 702 a asdescribed herein. Specifically, an installer may adhesively bond themechanical fastening component 708 with the adhesive tape 704 a of thefirst roofing membrane 702 a as described above, or the mechanicalfastening component 708 may be pre-applied to the first roofing membrane702 a. When the mechanical fastening component 708 is pre-applied to thefirst roofing membrane 702 a, the adhesive tape 704 a shown in FIG. 7Cmay represent the mechanical fastening component 708.

A mechanical fastener 712, such as a bolt or screw, is disposed throughone of the hole 710 of the mechanical fastening component 708 to couplethe first roofing membrane 702 a with the roof surface. A mechanicalfastener 712 may similar be positioned through the other holes 710 ofthe mechanical fastening component 708 to couple the first roofingmembrane 702 a to the roof surface.

An edge of a second roofing membrane 702 b is positioned atop andcoupled with the adhesive tape 704 a (or mechanical fastening component708) of the first roofing membrane 702 a. Specifically, the adhesivetape 704 b of the second roofing membrane 702 b is adhered to theadhesive tape 702 a of the first roofing membrane 702 a. Edges or sidesof the adhesive tapes, 704 a and 704 b, may be offset from one anotheror aligned as described herein. In some embodiments, the adhesive tape704 b of the second roofing membrane 702 b may be disposed fully aroundthe mechanical fastening component 708 as illustrated in FIG. 7C. Insuch embodiments, the adhesive tapes, 704 a and 704 b, may encase orenclose the mechanical fastening component 708 and effectively seal themechanical fastening component 708 from the surrounding environment. Inother embodiments, the adhesive tape 704 b of the second roofingmembrane 702 b may only surround or enclose a portion of the mechanicalfastening component 708, or the mechanical fastening component 708 maybe sized and shaped similar to the adhesive tape 704 b.

Although FIG. 7C illustrates only one side of the first roofing membrane702 a and the second roofing membrane 702 b, it should be realized thatthe opposite sides of the respective roofing membranes may be similarlycoupled with the roof surface and/or an adjacent roofing membrane. Forexample, the opposite side of the second roofing membrane may be coupledwith a mechanical fastening component 708 and an adhesive tape of athird roofing membrane in a manner similar to that illustrated in FIG.7C. In other embodiments, the opposite side of the first roofingmembrane 702 a and/or second roofing membrane 702 b may be adhesivelybonded to an adjacent roofing membrane without using a mechanicalfastening component 708.

In some embodiments, the mechanical fastening component 708 may beembedded within the adhesive tape 704. In such instances, the adhesivetape 704 may be attached to one or more sides or edges of the roofingmembrane 702 as described herein with the mechanical fastening component708 disposed or embedded within the adhesive tape 704. Such embodimentseliminate the need for the mechanical fastening component 708 to beattached or adhered to the adhesive tape 704 in a subsequent process.The releasable liner 706 may be perforated or otherwise marked so as toindicate or identify the holes 710 that a mechanical fastener ispositioned through to secure the roofing membrane 702 to a roof surface.The mechanical fastener may be positioned through the holes 710 usingthe perforations or markings of the releasable liner 706 and then theliner 706 may be removed to allow the roofing membrane 702 to beattached or coupled with an adjacent membrane. In some instances, themechanical fastening component 708 may be embedded or disposed withinthe adhesive tape 704 by sandwiching the mechanical fastening component708 between a pair of adhesive tapes. In other instances, the adhesivetape 704 may include a groove, slot, or depression within which themechanical fastening component 708 is positioned.

Referring now to FIGS. 8A-C, illustrated is another embodiment 800 of aroofing membrane 802 having pre-applied adhesive strips or tapes, 804 aand 804 b, (hereinafter adhesive tapes 804 a and 804 b) that areconfigured to facilitate in application of a mechanical fasteningcomponent attaches or secures the roofing membrane 802 to the roofsurface. Specifically, one side of the roofing membrane 802 includes apair of adhesive tapes, 804 a and 804 b, instead of a single adhesivetape 704 as shown in FIGS. 7A-C. The adhesive tapes, 804 a and 804 b,are applied to the roofing membrane 802 so that a gap 807 exists betweenthe adhesive tapes 804 a and 804 b. The outer most adhesive tape 804 amay extend outward from an edge of the roofing membrane 802 as shown, ormay be substantially aligned with the edge of the roofing membrane 802.The adhesive tapes, 804 a and 804 b, typically have a similar width,length, and thickness, but one or more of these parameters may be varieddepending on the application or need of the roofing membrane 802, or forvarious other reasons.

The gap 807 between the adhesive tapes, 804 a and 804 b, may be betweenabout 0.5 and 4 inches, and more commonly between about 0.5 and 1.5inches. The gap 807 is typically sized and shaped to accommodate amechanical fastening component. A releasable liner, 806 a and 806 b, isapplied atop each of the adhesive tapes, 804 a and 804 b, asillustrated. The releasable liners, 806 a and 806 b, conceals andprotects the adhesive material of adhesive tapes, 804 a and 804 b, fromdegradation or other fouling. In some embodiments, the releasableliners, 806 a and 806 b, may be separate liners while in otherembodiments a single releasable liner may be used to cover both adhesivetapes 804 a and 804 b. An exemplary embodiment of a releasable liner 912that may be used to cover the adhesive tapes, 804 a and 804 b, isillustrated in FIG. 9B.

The opposite side and surface (e.g., bottom surface) of the roofingmembrane 802 may also include an adhesive tape. The adhesive tape may bea single solid tape material 805, such as those described herein andillustrated in FIG. 8A, or may be a pair of adhesive tapes similar tothe adhesive tapes 804 a and 804 b.

FIG. 8B illustrates a mechanical fastening component 808 being coupledwith the adhesive tapes, 804 a and 804 b, of roofing membrane 802. Insome embodiments, the mechanical fastening component 808 is positionedwithin the gap 807 between the adhesive tapes 804 a and 804 b. In suchembodiments, the adhesive tapes, 804 a and 804 b, may adhesively bondonly with respective sides of the mechanical fastening component. Assuch, a top surface of the adhesive tapes, 804 a and 804 b, may berelatively free to directly adhesively bond with the adhesive tape of anadjacent roofing membrane. A main body of the mechanical fasteningcomponent 808 may be mechanically fastened or adhesively bonded directlywith the roofing membrane 802. The configuration of FIG. 8A may findparticular usefulness when the mechanical fastening component 808 isnarrower or substantially the same width as the gap 807.

In other embodiments, the mechanical fastening component 808 may beadhered or secured to the roofing membrane 802 via the adhesive tapes804 a and 804 b. Specifically, the opposing sides or edges of themechanical fastening component 808 may be adhesively bonded with theadhesive tapes 804 a and 804 b. The opposite side of the roofingmembrane (i.e., the right hand side of FIG. 8B) may similarly include amechanical fastening component 808, or may only include the adhesivetape 805. In any event, the mechanical fastening component typicallyincludes a plurality of holes 810 that are configured for receiving amechanical fastening component, such as a bolt or screw.

An installer may position the mechanical fastening component 808 withinthe gap 807 and/or between the adhesive tapes, 804 a and 804 b, prior tocoupling the roofing membrane 802 with a roof surface. The installer mayadhere the mechanical fastening component 808 within the gap 807 and/orremove a releasable liner on a pre-applied adhesive material within thegap 807 to attach the mechanical fastening component 808 with theroofing membrane 802. In other instance, the mechanical fasteningcomponent 808 may be pre-applied to the roofing membrane 802 within thegap 807 so that installation of the mechanical fastening component 808by an installer is not needed.

Referring now to FIG. 8C, the installation of the roofing membrane to aroof is illustrated. Specifically, a mechanical fastening component 808is positioned between adhesive tapes, 804 a and 804 b, of a firstroofing membrane 802 a. A mechanical fastener 812 is then insertedthrough one or more holes 810 of the mechanical fastening component 808to secure the first roofing membrane 802 with the roof surface. An edgeor side of a second roofing membrane 802 b is then positioned over theside or edge of the first roofing membrane 802 a that is secured withthe roof surface. The adhesive tape 805 of the second roofing membrane802 b is then adhesively bonded or coupled with the adhesive tapes, 804a and 804 b, of the first roofing membrane 802 a. Releasable liners (notshown) of the respective adhesive tapes (i.e., 805, 804 a and 804 b) areremoved sometime prior to coupling the first roofing membrane 802 a andsecond roofing membrane 802 b.

The adhesive tape 805 of the second roofing membrane 802 b may be offsetfrom the edge or side of one or both adhesive tapes, 804 a and 804 b, asillustrated, or may be substantially aligned with a side or edge of oneor both adhesive tapes, 804 a and 804 b, as desired. In additional,although FIG. 8C illustrates the second roofing membrane 802 b includinga single adhesive tape 805, in some embodiments the second roofingmembrane may include a pair of adhesive tapes (not shown) similar to theconfiguration of the adhesive tapes, 804 a and 804 b, of the firstroofing membrane 802 a.

One advantage of the roofing membrane configuration of FIG. 8C is thatthe mechanical fastening component 808 is entirely enclosed and sealedby the adhesive tapes (i.e., 805, 804 a and 804 b) of the first andsecond roofing membranes, 802 a and 802 b. The adhesive tapes (i.e.,805, 804 a, and 804 b) are also able to directly adhesively bond withone another, which may improve the water proofing of the roofing system.

The opposite side or edge of the first roofing membrane 802 a and/orsecond roofing membrane 802 b may be coupled with an adjacent roofingmembrane in a manner similar to that illustrated in FIG. 8C. In otherembodiments, the opposite side or edge of the first roofing membrane 802a and/or second roofing membrane 802 b may be adhered directly to theadhesive tape (or directly to the roofing membrane) of an adjacentroofing membrane without using a mechanical fastening component 808.

Referring now to FIGS. 9A and 9B, illustrated are exemplary releasableliners that may be used to cover and protect the adhesive tapes (ormechanical fastening components) of the roofing membranes of FIGS.7A-8C. The releasable liners include scored sections that enable aninstaller to easily locate a position for the mechanical fasteningcomponent or mechanical fasteners. For example, the releasable liner maybe used to align the mechanical fastening component with the adhesivetape and/or align the mechanical fastener about a fastening hole in themechanical fastening component.

Referring to FIG. 9A, the releasable line 902 includes a main body thatis typically rectangular in shape and sized slightly larger than theadhesive tape or mechanical fastening component atop which it isapplied. The releasable line 902 includes a plurality of scored orperforated sections 904 that may easily detach from the main body of thereleasable line 902. The scored or perforated sections 904 commonlycorrespond to the fastening holes 710 of the mechanical fasteningcomponent 708. The scored or perforated section 904 may be aligned withthe fastening holes 710 of the mechanical fastening component 708 toensure that the mechanical fastening component 708 is properly alignedwith the adhesive tape 804. To aid in alignment, the scored orperforated sections 904 may be a different color than the main body ofthe releasable line 902 or may include other marking that make thescored or perforated sections easily identifiable and visible. In someembodiments, the main body of the releasable line 902 may be peeled offof the adhesive tape and the scored or perforated section 904 may remainattached to the adhesive tape. In this manner, the scored or perforatedsections 904 may be used for alignment of the mechanical fasteningcomponent 708 even after the releasable liner 902 is removed. Themechanical fastening component 708 may then be pressed onto the adhesivetape, which may secure the mechanical fastening component 708 inposition until the mechanical fasteners are inserted through thefastening holes 710.

Removing the releasable liner 902 to expose the underlying adhesive tapeprovides a tacky surface that grips or sticks to the mechanicalfastening component 708. Placing the mechanical fastening component 708on the exposed adhesive tape ensures that the mechanical fasteningcomponent 708 is held it in place during installation of the roofingmembrane. This function may be especially with polymer materialmechanical fastening components 708, which may be inclined to curl up inthe longitudinal direction. The curling of the mechanical fasteningcomponents 708 may be especially prevalent when the mechanical fasteningcomponent 708 is wound and stored for shipping. The exposed adhesivetape secures and holds the mechanical fastening component 708 on theroofing membrane making it relatively easy for an installer to drive themechanical fastener through the fastening holes 710.

When the mechanical fastening component 708 is pre-assembled or appliedto the roofing membrane, the scored or perforated sections 904 may bedisposed immediately above the fastening holes 710 to identify thelocation of the holes. The scored or perforated section 904 may beremoved and mechanical fasteners inserted through the fastening holes710 to secure the roofing membrane to the roof surface. The remainder ofthe releasable liner 902 may then be subsequently removed. In otherembodiments, the mechanical fastening component 708 may not beadhesively bonded to the adhesive tape 704. In such embodiments, acenter strip of the perforated liner (i.e., 914 of FIG. 9B or the centerportion of liner 902) may be removed to hold the mechanical fasteningcomponent 708 in position while the mechanical fasteners are attached.The outer strips or portions of the liner 902 or 912 may then be removedto imbed the fasteners.

Referring to FIG. 9B, another releasable liner 912 is illustrated. Thereleasable liner 912 of FIG. 9B includes a scored or perforatedmid-section 914 that corresponds to the gap 807 that exists between theadhesive tapes, 804 a and 804 b, of the roofing membrane 802. The scoredor perforated mid-section 914 aids in aligning the mechanical fasteningcomponent 808 by identifying where the gap 807 is located. In operation,the scored or perforated mid-section 914 may be detached and removedfrom the remainder of the releasable liner 912, such as by peeling thissection 914 away from the releasable liner 912. The mechanical fasteningcomponent 808 may then be positioned within the gap 807 and secured tothe roofing membrane and/or roof surface as described herein. Theremaining portions of the releasable liner 912 may then be removed toexpose the adhesive material of the adhesive tapes 804 a and 804 b.

In some instances an adhesive tape that is pre-applied to a roofingmembrane may partially or fully cure while in storage and/or transport,especially when the roofing membrane is stored for an extensive periodof time. The adhesive tape may also have a propensity to stick to othersurfaces that it contacts during handling and prior to final placementof the roofing membrane. To alleviate some or all of these issues, aroofing system may include multiple materials or layers that react uponcontact. The multiple materials or layers may ensure that thedevelopment of high adhesion occurs after the installation of theroofing membrane is complete and not prior to installation, such asduring storage or transport. The multiple layers can consist of tapeshaving different chemical compositions, such as pre-applied adhesivelayers that reactively cure together. In other embodiments, the multiplelayers may include a combination of a reactive tape and an adhesivematerial.

Referring now to FIGS. 10A-C, illustrated is an embodiment of a roofingmembrane 1002 having a reactive material that is applied to at least onesurface of the roofing membrane 1002. In some embodiments, the reactivematerial may be applied to opposite surfaces and opposite sides or edgesof the roofing membrane 1002 as previously described. In otherembodiments, the reactive material may be applied to a single surface(i.e., either top or bottom) and a single side of the roofing membrane,or may be applied to the same surface (i.e., either top or bottom) andopposite sides of the roofing membrane 1002. FIG. 10A illustrates theroofing membrane 1002 having a first reactive material 1006 applied to atop surface and one extreme edge or side of the membrane 1002 and asecond reactive material 1004 applied to a bottom surface and anopposite extreme edge or side of the membrane 1004.

The first reactive material 1006 is an “A” part of a chemically reactivetwo-part cure system while the second reactive material 1004 is a “B”part of the chemically reactive two-part cure system. In otherembodiments, the first reactive material 1006 and the second reactivematerial 1004 may both be either “A” parts or “B” parts of a chemicallyreactive two-part cure system. In such embodiment, the first reactivematerial 1006 and second reactive material 1004 may be positioned on thesame surface and opposite sides, or opposite surfaces and opposite sidesas illustrated. The “A” part and “B” part may be configured to reactwhen they contact one another and not prior to such contact. In someembodiments, the A and B parts may be polymer resins, synthetic resins(e.g., epoxy), natural resins, and the like. The “A” part and “B” partreactive layers or materials may be applied as a tape that is adhesivelybonded to the roofing membrane, applied to or soaked in a carriermaterial that is attached to the roofing membrane, or applied as aliquid directly to the roofing membrane. In a specific embodiment, atleast one of the first reactive material 1006 or second reactivematerial 1004 is applied as a tape. In another embodiment, both thefirst reactive material 1006 and the second reactive material 1004 areapplied as tapes or carriers. In yet another embodiment, the firstreactive material 1006 and the second reactive material 1004 are appliedin different manners, such as one being applied as a tape or carrier andthe other being applied as a liquid.

When a tape or carrier material is used, the tape or carrier materialmay be offset from an edge or side of the roofing membrane 1002, orsubstantially aligned therewith as previously described. Exemplary Apart and B part materials include: epoxies, urethanes, polyurethanes,polysulfides, acrylics, polyesters, polyureas, silicones, and the like.FIG. 10 B illustrates a side view of the roofing membrane 1002 havingthe first reactive material 1006 applied to the top surface and oneextreme side or edge and the second reactive material 1004 applied tothe bottom surface and opposite extreme side or edge.

FIG. 10C illustrates a first roofing membrane 1002 a adhesively bondedwith a second roofing membrane 1002 b. The first roofing membrane 1002 aincludes a second reactive material 1004 having a B part of a chemicallyreactive two-part cure system as previously described. The secondroofing membrane 1002 b includes a first reactive material 1006 havingthe A part of the chemically reactive two-part cure system. The firstand second roofing membranes, 1002 a and 1002 b, are positioned relativeto one another so that the second reactive material 1004 is positioneddirectly atop and in contact with the first reactive material 1006.Contact between the first and second reactive materials, 1006 and 1004,causes the reactive materials to cure and adhere together. Specifically,contact between the A part and B part of the chemically reactivetwo-part cure system effects a chemical reaction that adhesively bondsthe first and second roofing membranes, 1002 a and 1002 b, together atthe seam. In some instances, the reaction of the A and B part materialsmay be incrcased upon application of heat and/or pressure. When eitherthe first reactive material 1006 and/or second reactive material 1004are applied as tapes or carriers, the reactive material may be offsetfrom a side or edge of the seam between the first and second roofingmembranes, 1002 a and 1002 b, or may be substantially aligned therewith.

In some instances, it may be difficult to roll and/or transport roofingmembranes that include pre-applied adhesive tapes as described herein.For example, the pre-applied adhesive tape roofing membranes may notwind-up or kickout smoothly due to an inconsistent thickness across theroofing membrane sheet. These issues may be alleviated by employing afolding orientations that improves the wind-up of the roofing membrane.The folding orientation employed may distribute more material in thethinner sections of the roofing membrane sheet and thereby avoid some ofthe problems associated with rolling the roofing membrane.

FIG. 11A illustrates one embodiment of a folding orientation that may beemployed to alleviate some of the issues associated with rolling theroofing membrane sheet. FIG. 11A illustrates a roofing membrane 1102having a configuration similar to those described herein. Specifically,the roofing membrane 1102 includes a first material 1104 and a secondmaterial 1106 that are attached to opposite extreme sides or edges ofthe roofing membrane 1102. The first and second materials, 1104 and1106, may be attached to the same side or surface of the roofingmembrane, or may be attached to opposite sides or surfaces of theroofing membrane 1102 as illustrated in FIG. 11A. The first and secondmaterials, 1104 and 1106, are representative of the various materialsdescribed herein, including: pre-applied adhesive tapes, mechanicalfastening members, reactive materials (e.g., A and/or B part materials),and the like. The first and second materials, 1104 and 1106, may also berepresentative of other materials that are not described herein. Assuch, the first and second materials, 1104 and 1106, are not limited toany one particular roofing membrane embodiment.

As illustrated in FIG. 11A, the roofing membrane 1102 is Z-folded 1108between the first and second materials 1104 and 1106. Specifically, theroofing membrane 1102 is Z-folded 1108 to include three folded layersthat “build up” or result in a similar thickness as the roofing membrane1102 and the first and second materials 1104 and 1106. Stateddifferently, the roofing membrane 1102 is folded so that the centralZ-folded section 1108 has a thickness that is similar to the thicknessof one or both sides or edges of the roofing membrane 1102, whichincludes the thickness of the roofing membrane sheet and the respectivefirst material 1104 or second material 1106. Ideally, the folded centralsection of the roofing membrane has a thickness that is equivalent to orgreater than the thickness of each side or edge. This thicker centralsection configuration ensures that when the roofing membrane 1102 isstacked with other similar roofing membranes, the stacking pressure isexerted on the central folded section and not on the ends that includethe first and second materials, 1104 and 1106. Eliminating or reducingpressure that is exerted on the first and second materials, 1104 and1106, may help ensure that premature curing or other issues, such ascompression of the respective materials, does not occur or is minimized.

In some embodiments, the roofing membrane 1102 is folded so that thefolded central section 1108 occurs between the inner edges or sides ofthe first and second materials 1104 and 1106. Stated differently, thefolds of the central section are disposed inside or in-between the firstand second materials, 1104 and 1106, so that the folds and roofingmembrane sheet do not contact, or minimally contact, the first andsecond materials 1104 and 1106. This configuration helps ensure that thefirst and second materials, 1104 and 1106, are free of the centralfolded section 1108 and that stacking pressure are not transferred tothe first and second materials 1104 and 1106.

FIG. 11B illustrates an embodiment of a roofing membrane 1120 thatincludes a pre-applied tape 1122 that is applied to only a single sideof the roofing membrane 1120. The opposite side of the roofing membrane1120 may not include a tape or other material or may include a materialhaving a negligible thickness, such as a reactive material that isapplied as a liquid to the roofing membrane 1120. The application of thepre-applied tape 1122 to a single side of the roofing membrane 1120 mayresult in an imbalance of the roofing membrane 1120, particularly animbalance of the thickness of the roofing membrane 1120. To balance thethickness of the roofing membrane 1120, a filler strip or material 1124may be placed at a side or edge of the roofing membrane 1120 oppositethe pre-applied tape 1122. The filler strip 1124 may be applied to thesame surface or an opposite surface of the roofing membrane depending onthe balance that is desired. The roofing membrane may then be folded asdescribed in FIG. 11A. In some embodiments, the filler strip 1124 mayaid in rolling the roofing membrane 1120 out straight, and/or the fillerstrip 1124 could have an anti-slip or light tack surface that preventsthe fold from slipping laterally or wrinkling during winding up. In yetother embodiments, the filler strip 1124 may be composed of membraneand/or tape materials and may be used to patch or flash details on theroofing membrane and/or roof surface. Alternatively, the filler strip1124 may have a non-stick surface and may be placed strategically toprevent the adhesive tape 1122 from sticking to the wrong surfacesduring installation, such as sticking to an adjacent roofing membranesheet when the roofing membrane is folded back in a butter-flyapplication.

FIG. 11C illustrates another embodiment of a fold that may be employedfor roofing membranes. Specifically, the roofing membrane 1130 in FIG.11C includes a pre-applied tape 1132 on opposite extreme sides or endsand on the same surface (e.g., top surface). The roofing membrane 1130is folded roughly centrally so that the two sides or ends are slightlyoffset from one another, which avoids the pre-applied tapes 1132 frombeing positioned atop one another. Since the pre-applied tapes 1132 arenot positioned atop one another, the folding of the roofing membrane1130 does not result in a “double-thickness” at the end of the roofingmembrane where the pre-applied tapes 1132 are positioned. A filler strip1124 is inserted inside the folded roofing membrane 1130 to mimic thethickness of the pre-applied tapes 1132. The filler strip 1124 may bepositioned at the fold of the roofing membrane 1130 or elsewhere asdesired. In some embodiments, the filler strip 1124 may extend from nearthe fold to adjacent one of the pre-applied tapes 1132. In suchembodiments, the filler strip 1124 may be slightly thicker than thepre-applied tapes 1132 so that a majority of a downward force is appliedto the filler strip 1124 and not the pre-applied tapes 1132. Thethickness of the filler strip 1124 is typically chosen to ensure thattension during wind-up and kickout of the roll is equal on both sides.

According to one embodiment, a method of forming a roofing membraneincludes providing a main body of the roofing membrane. The main bodyhas a top surface, a bottom surface positioned opposite the top surface,and four edges that define an outer periphery of the main body such thatthe main body has a rectangular or square profile. The method alsoincludes applying a first material to the main body so that the firstmaterial is positioned toward a first edge thereof and applying a secondmaterial to the main body so that the second material is positionedtoward a second edge thereof. The first material may extend along amajority of a length of the first edge and the second material mayextend along a majority of a length of the second edge. Typically bothmaterial extend along substantially all or all of the length of thefirst edge and second edge respectively. The second edge may bepositioned opposite the first edge such that the first and secondmaterials are positioned toward opposite edges of the main body and insome embodiments on opposite surfaces thereof, although the first andsecond materials may be positioned on the same surface (i.e., either topor bottom).

In some embodiments, at least one of the first material or the secondmaterial includes a first reactive material of a chemically reactivetwo-part cure system that is configured to chemically react upon contactof the first reactive material with a second reactive material of thechemically reactive two-part cure system. In some embodiments, the firstmaterial may be or include the first reactive material and the secondmaterial may be or include the second reactive material so that theroofing membrane includes both materials of the chemically reactivetwo-part cure system positioned on opposite edges of the main body. Themethod may further include applying the first reactive material as aliquid directly to a surface of the roofing membrane. In otherembodiments, the method may further include applying the first reactivematerial as a tape to a surface of the roofing membrane or saturatingthe first reactive material in a carrier that is attached to the roofingmembrane.

In other embodiments, the first material may be or include an adhesivetape that is bonded with the roofing membrane. In such embodiments, themethod may additionally include adhesively bonding a mechanicalfastening member with a top surface of the adhesive tape. The mechanicalfastening member may be configured to receive a mechanical fastener tosecure the roofing membrane to a roof surface. In yet other embodiments,the first material may be a mechanical fastening member that isconfigured to receive a mechanical fastener to secure the roofingmembrane to a roof surface. The mechanical fastening member may becoupled with the roofing member prior to transport of the roofing memberto an installation site.

In yet other embodiments, the first material may include a pair ofadhesive tapes that are bonded to the main body and positioned towardthe first edge with a gap existing between the inner sides or edges ofthe pair of adhesive tapes. The gap may be sized so that a mechanicalfastening member may be positioned therein. The mechanical fasteningmember may be configured to receive a mechanical fastener to secure theroofing membrane to a roof surface.

In some embodiments, the method may additionally include removablysecuring a releasable liner atop the first material. The releasableliner may include at least one scored or perforated region that isindependently removable from a main body of the releasable liner. Insuch embodiments, the method may also include removing the main body ofthe releasable liner or the at least one scored or perforated region ofthe releasable liner from the first material so that either the mainbody of the releasable liner or the at least one scored or perforatedregion of the releasable liner remains attached to the first material.The at least one scored or perforated region of the releasable liner maybe positioned with respect to the main body of the releasable liner soas to aid in alignment of a mechanical fastening member with the firstmaterial. In such embodiments, the method may further include aligningthe mechanical fastening member with the first material via the at leastone scored or perforated region.

The method may additionally include folding the roofing membrane in az-configuration with the folded section of the roofing membrane beingdisposed between the first material and the second material.

Although the figures and the embodiments described are generallydirected toward roofing membranes having an adhesive tape or othermaterial applied to opposing sides and opposing surfaces, it should berealized that many variations are possible. For example, in someembodiments, the adhesive tape or other material may be positioned oneach edge so that all four edges or sides includes an adhesive tape orother material. In such instances, the adhesive tape or material may bepositioned on opposing sides of the roofing membrane in any combination,or may be positioned on the same side. In other embodiments, three ofthe four sides or edges may include an adhesive tape or other material,which may each be positioned on the same surface or on opposing surfaceas desired.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

What is claimed is:
 1. A roofing membrane comprising: a main bodyhaving: a top surface; a bottom surface positioned opposite the topsurface; and four edges that define an outer periphery of the main bodysuch that the main body has a rectangular or square profile; a firsttape or carrier material bonded to the top surface of the main body andpositioned toward a first edge thereof, the first tape or carriermaterial extending along a majority of a length of the first edge; and asecond tape or carrier material bonded to the bottom surface of the mainbody and positioned toward a second edge thereof, the second tape orcarrier material extending along a majority of a length of the secondedge; wherein: the second edge is positioned opposite the first edgesuch that the first and second tape or carrier materials are positionedtoward opposite edges of the main body, a first reactive material of achemically reactive two-part cure system is applied to or soaked in thefirst tape or carrier material; a second reactive material of thechemically reactive two-part cure system is applied to or soaked in thesecond tape or carrier material; and the first reactive material isconfigured to chemically react upon contact with the second reactivematerial and is further configured to not chemically react prior tocontact with the second reactive material.
 2. The roofing membrane ofclaim 1, further comprising a first membrane material releasably coupledwith a top surface of the first reactive material and a second membranematerial releasably coupled with a top surface of the second reactivematerial.
 3. The roofing membrane of claim 1, wherein the first reactivematerial and the second reactive material are resins.
 4. The roofingmembrane of claim 1, wherein the first tape or carrier material isbonded to the main body such that an edge of the first tape or carriermaterial extends outwardly of the outer periphery from an edge of themain body by between about 1/16 and ¼ inch.
 5. A roof membrane systemcomprising: a first membrane positioned atop the roof, the firstmembrane having a distal edge that includes a tape or carrier materialon a top surface thereof, the tape or carrier material extending along amajority of a length of the distal edge, wherein a of a chemicallyreactive two-part cure system is applied to or soaked in the tape orcarrier material of the first membrane; and a second membrane positionedatop the roof and adjacent the first membrane so that a proximal edge ofthe second membrane overlaps with and is bonded to the distal edge ofthe first membrane, the proximal edge of the second membrane including atape or carrier material on a bottom surface thereof, the tape orcarrier material extending along a majority of a length of the proximaledge, wherein a second reactive material of the chemically reactivetwo-part cure system is applied to or soaked in the tape or carriermaterial of the second membrane; wherein the first reactive material andthe second reactive material are configured to chemically react and cureupon contact with one another to bond the distal edge of the firstmembrane to the proximal edge of the second membrane, and wherein thefirst reactive material and the second reactive material are configuredto not chemically react prior to contact with one another.
 6. The roofmembrane system of claim 5, further comprising a first membrane materialreleasably coupled with a top surface of the first reactive material anda second membrane material releasably coupled with a top surface of thesecond reactive material.
 7. The roof membrane system of claim 5,wherein the first reactive material and the second reactive material areresins.
 8. A roofing membrane comprising: a main body having: a topsurface; a bottom surface positioned opposite the top surface; and fouredges that define an outer periphery of the main body such that the mainbody has a rectangular or square profile; a first tape or carriermaterial bonded to the main body and positioned toward a first edgethereof, the first tape or carrier material extending along a majorityof a length of the first edge, wherein a first reactive material of achemically reactive two-part cure system is applied to or soaked in thefirst tape or carrier material; and a second reactive material of thechemically reactive two-part cure system bonded to the main body andpositioned toward a second edge thereof, the second reactive materialextending along a majority of a length of the second edge; wherein: thesecond edge is positioned opposite the first edge such that the firstand second materials are positioned toward opposite edges of the mainbody; wherein the first tape or carrier material is bonded to the mainbody such that an edge of the first tape or carrier material extendsoutwardly of the outer periphery from an edge of the main body bybetween about 1/16 and ¼ inch; and the first reactive material isconfigured to chemically react upon contact with the second reactivematerial and is further configured to not chemically react prior tocontact with the second reactive material.
 9. The roofing membrane ofclaim 8, wherein the second reactive material is applied as a liquiddirectly to the roofing membrane surface.
 10. The roofing membrane ofclaim 8, wherein the second reactive material is applied to or soaked ina second tape or carrier material that is bonded to the main body. 11.The roofing membrane of claim 8, further comprising a first membranematerial releasably coupled with a top surface of the first reactivematerial and a second membrane material releasably coupled with a topsurface of the second reactive material.
 12. The roofing membrane ofclaim 8, wherein the first reactive material and the second reactivematerial are resins.